Method for treating upholstery and floor covering materials



Sept. 29,

T. J. BOWES METHOD FOR 'IIREATING UPHOLSTERY AND FLOOR OVERING MATERIALSFiled April 10|, 1934 gosgvg gglugqgag. g

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INVENTOR ORNEYS i Patentedl Sept.' 29, 1936 UNITED s- TATES PATENT ioFFIcE METHOD FOR TREATING UPHOLSTERY kAND FLOOR COVERING MATERIALSTheodore J. Bowes, Passaic, N. J., assigner, by mesne assignments, toAndrew McLean vCom-- pany, Passaic, N. J., a corporation of New JerseyApplicationApril 10, 1934, Serial No. 719,840 Y "i claims. (ci.:s1-ssl'A Y My invention relates to an improved method and means fortreating upholstery and ioor coverings such as rugs, carpets, linoleums,etc. to render them fray-proof, and more particularly to the modo ofapplication of an adhesive synthetic resin plastic type composition tothe base of pile fabric typeupholstery or rug or carpet* material tohold the pile firmly n the base.

Numerous attempts have been made in the prior art to protect rugs,carpets and other floor coverings against fraying but apparently theyare all subject to inherent disadvantages which up until the presenttime have made them commercially unsatisfactory. One of therepresentative types of prior art processes comprises applying to thebase 0f rug or carpet material a rubber composition such as the oneknown to the trade as latex. 'I'his type of composition has initiallythe desired characteristics, that is, it will hold the pile in the baseof the rug, but after some ordinary period of use the rubber willstretch or lose its elasticity, in accordance with its inherentcharacteristics, so that it is no longer suitable for its intended use.Still another and an even more important disadvantage is that thisrubber composition will become rancid due to oxidation and give oi adisagreeable odor, which of course substantially diminishes the value ofthe rug or carpet to which it is applied.

In accordance with my 'invention I treat the base of the upholstery orfloor covering material, such as rug or carpet material, with a specialtype of adhesive, synthetic resin, plastic composition which I havedeveloped. Due to the inherent ,characteristics of this composition andparticularly to the manner in' Which'I apply the composition to themateriali'the limitations and disadvantages of the prior art, such, forexample, as those described above, are substantially overcome. 4

One of the important features of my invention, which is described indetail hereinafter is the particular manipulation of the upholstery oroor covering material during the part of theprocess in which the base ofthe material is being impregnated with'the adhesive composition. Thismanipulation consists essentially in iiexing or bending the material insuch a manner that the interstices between the threads forming the baseof the material are greatly enlarged, thus4 carpet or the liketo whichitis applied. Also,

. it is of such a nature that it does not give rise to any disagreeableodors due to chemical changes that may take place in the composition. Bythe use of this composition and my improved method of applying it,upholstery, rugs, carpets and other floor `covering materials can bemade more nearly fray-proof and at substantially less cost than by anyof the prior art methods of which I am aware.

The fray-proof characteristic of the floor coverings treated inaccordance with my invention adds materially to their usefulness andversa` tlllty. For example, a carpet so treated may be cut into stripswithout the cut. edges becoming frayed or ravelled out. This is ofparticular importahce where it is desired to use a single strip oi thematerial, for example, a runner for a corridor.

In another modification of my' invention a rug may have sections cut outof its body of different shapes and designs and these 4cut-out sectionsreplaced by similarly shaped sections of dif-- ferent color or ofdifferent material to give the rug an unusual and attractive appearance.25.

secondly, to employ some simple means of se` curely attaching theinserted sections to the main body of the rug. The latter may be done,of 35 course, by stitching the adjacent edges of the rug and theinsertions but this proves to be expensive, and, furthermore, mars theappearance of the finished product so that this method defeats theentire purpose of the modification and therefore o is `not satisfactory.I accomplish this necessary uniting of the several parts of the modiedrug in an eflicient and simple manner. 'I'he details of this part of myinvention are described hereinafter but the method consists essentiallyin wet- 45 ting the previously coated back of the rug along the'edges ofthe cut-out sections with a suitable solvent for 'the coating and thenjoining the inserted portions with the cut edges of the rug byapplying'thereto a narrow strip of fabric which is coated with asomewhat similar adhesive yresinous composition. No heat 'or pressureneed be used. The final product produced b`y the above method is notsubject to the objections characteristic of the prior art which make thenished rug appear unattractive. In the conformed rugs of my inventionthere is no apparent connecting line between the body of the rug and theinserted portions so that for ordinary general observation the rugappears to be woven in one single piece. It is of course evident that myabove described process for making novel rug designs may be ap-` pliedequally as well .to carpets and other floor covering materials.

It is well recognized that to produce a seamless carpet, that is,`onewoven to the exact width of the room in which it isto be used ratherthan in narrow strips, 'usually thirty-six inches wide, necessitatesgreat expense. The demand for seamless carpets has grown rapidlyinrecent years, however, so that any method or means which could bedeveloped for making them less expensive would constitute a greatadvance in the art technically and commercially. In accordance with myinvention I am able to join strips of carpet, for example thirty-sixinches wide, in such a manner that the finished carpet has a seamlessappearance and the method involves comparatively little expense. 'I'hemethod consists essentially in first fray-proofing' the strips of carpetby coating the back of the strips with my 4improved adhesive resinousplastic composition and then joining the strips by moistening thecoating along the edges of the carpet and applying thereto an adhesivefabric strip.

An object of my invention is to provide improved methods and means fortreating uphol- 'stery and floor covering materials to render themfray-proof.

Another object of my invention is to provide a method and means forutilizing an adhesive synthetic resin base plastic composition to joinseparate pieces of upholstery, or iioor covering material in such amanner that the iinished product appears to be made from a single pieceof material.

While the constituents and proportions may be varied widely, thefollowing Example I will illustrate the type of composition that I usefor rendering upholstery, and floor covering materials such as rugs andcarpets fray-proof, and Example II illustrates a suitable compositionfor treating the fabric strips that I use for uniting separate pieces-of the upholstery and oor covering material.

Example I Per cent Synthetic resin (e. g. a resin 'of the toluenesulfonamide class) 21 Solvent (e. g. acetone) 69 Plasticizer (e. g.diethyl phthalate) 7 Cellulose derivative (e. g. cellulose acetate) 3Example II Per cent Synthetic resin (e. g. a resin of the toluenesulfonamide class) 24 Solvent (e.'g. acetone) 63 Plasticizer (e. g.diethyl phthalate) 7 Cellulose derivative (e. g cellulose acetate) 6 Itwill be understood that the solvent 'win be' chosen with due regard tothe nature of the resin and cellulose derivative employed.' Othersynthetic resins suitable for the purposes of my invention are resins ofthe phenol-formaldehyde and rezyl types. Besides cellulose acetate,other suitable cellulose derivatives that might be mentioned are: ethylcellulose and cellulose nitrate.

Among the plasticizers that may be employed are the esters of phthalicand glycolic acids. It

is sometimes desirable to use more than one plasticizer in thecompositions. Also plasticizers of the reprooi type, forexamp1e,'triphen yl phosphate may be used to render the compositionfireproof.

It is important to note that the composition given in Example II hassubstantially higher percentages of the-solid constituents, namely,cellulose derivative and synthetic resin, and a lower percentage ofsolvent than the composition given in Example I. 'I'his increase insolid and decrease in liquid constituents produces a viscous mixturesuitable for coating and impregnatingthe fabric strips, which are usedfor uniting the separate pieces of oor covering material. A suitablemethod for preparing such fabrics is disclosed in my copendingapplication Serial No. 719,135, filed April 5, 1934.

`The novel features which I believe to be characteristic of my inventionare set forth with particularity in the appended claims. 'Ihe in ventionitself, however, both as to its organization and method of operation,will be fully understood by reference to the following more specificdescription taken in connection with the accompanying drawing, in which:

- Figure 1 represents diagrammatically a system for continuouslytreating upholstery and iloor covering material such as rug and carpetmaterial to render the same fray-proof.

Figure 2 is an exaggerated sectional view of a Small piece of carpetillustrating the exed condition of the carpet while it is being treatedwith the adhesive synthetic resin base plastic composition.

Figure 3 is an exaggerated sectional view of a small piece of carpetafter it has been treated, showing the impregnation of the base of thecarpet with the resinous plastic composition.

Figure 4 is a perspective view of two pieces of carpet which have beenmade fray-proof by treatment in the system of Figure 1 and are joinedtogether by means of an adhesive fabric strip;

Figure 5 is a plan view of the base of a rug, which has been madefray-proof by my process, and has an inserted portion of differentmaterial joined to the body of the rug to produce a novel rug design.

Referring now to Figure 1, one method suitable for fray-proofing,upholstery and iioor covering material in accordance with my invention,will be described. While it is to be understood of course that thematerial which is to be treated may be either pile fabric upholstery,rug, carpet, linoleum, or the like, for the sake of brevity andclearness of description, the material referred to in this specificexample will be termed carpet material.

The untreated carpet material is unwound from the supply roll III anddrawn around the tension rolls I I and-then under the first guiderollI2. This guide-roll I2 is mounted upon an arm I3 which is slidablyconnected to the cross member I4 supported by the two standards I5, thelatter being shown broken oi, for clearness of illustration. Connectedto this arm I3 is another arm I6 which is also slidably connected to thecross member I4. These two slidable or adjustable arms permit the rollI2 to be adjusted horizontally and vertically so as to obtain thecorrect amount of pressure applied by this roll to the strip of carpetmaterial represented here by the broken line II.l The dual purpose ofthis roll I2 is to guide the material Il, and at the suspended m thebowl u which is in tum supported bythe stand 2l. This roll Il is causedto rotate in a clockwise direction by some suitable driving means (notshown) attached to the shaftl The carpet material I1 is flexed or formedis positioned a hopper 23. 'Ihis hopper contains an adhesive syntheticresin base plastic composition 24 Yof the type described abpve. Thisinal terial is supplied to the hopper 24 as needed from be easilycontrolled. The pertinence of this fall or `drop of the composition isexplained below. To permit vertical adjustment the hopper 23 may beslidably mounted on the cross member I, or the member it itself may bevertically adjustable, by means of slidable connections Idd, .on thestandards it.

The method `of depositionof the composition 2t on the base of materialI1 and theilexed condition of the material I1 during this part of theprocess is clearly shown in Figure 2. As is seen from van observation ofthis vilgure, in"which the sizes of the component parts of the carpetma'- terial are greatly enlarged, the carpet -is formed around the rollI8 in a semi-circular manner. The longitudinal jute threads in the baseof the material are represented here in section by the two sets ofcircles 29. l The transverse jute thread which separates thelongitudinal jute threads 2Q is represented by the semi-circular member3i). The separate brush-like members 3 i which constitute the carpetpile, are anchored to the jute threads 29 and 30 by means of the twointerwoven roller-chain threads 32.

As is readily perceived from an inspection of Figure 2, the purpose ofilexing or bending the carpet material is to increase the openingsbetween the threads 29; 30 and 32 and between the looped yends ofadjacent piles 3i'to permit penetration therebetween of the .adhesiveresinous plastic composition 24. If this composition were deposited uponthe base of the carpet I1 without the latter being ilexed in some mannerthe composition would not penetrate into the base but instead would forma coating on the surface of the treads in the base and would therebyfail to cement the pile fibres to the jute and anchor threads. Thisdesired cementing is easily and effectively accomplished however whenthe carpet is flexed in the manner illustrated in Figures 1 and 2. y

It is to be noted also that the amount of penetration into the carpetbase by the composition 24 can be controlled somewhat by the height ofthe hopper 23 with respect to the carpet material I1 and by theconsistency of the composition 24. If the hopper 23 is positioned asubstanti'al distance .above the carpet material Il the composition 24flowing from the hopper 23 will fall upon the Vcarpet I 1 with sumcientforce to cause the composition to penetrate into the base oi the carpet.As suggested, this eil'ect can be enhanced by properly controlling theconsistency of the composition 24.

Referring again to Figurel l, as the treated carpet material leaves theexing roll I8 it passes under the second guide roll 22 which is mountedupon a slidable arm IZI. This roll 22 besides being a guide roll acts`also asl an impregnating roll for compressing the deposited composition24 into the base of the carpet. The desired amount of pressure exertedby this roll upon the carpet base and secondly the amount ofimpregnation of the deposited composition in the base of the carpet canbe easily established and maintained by proper`adjustment of the twoslidable arms I3 and IBto which the roll 22 is attached. The treatedcarpet after leaving the impregnating roll 22 passes over a guide-roll33 `and 4then through the aperture 34 into the treating chamber 35. Inone embodiment off this part of the syste of my invention the chamber 35is approximately 50 feet long and l0 feet vhigh and suiiiciently wide ofcourse to accommodate the width of the rug or carpet being treated. Thechamber 35 comprises a number of heating coils 36 mounted upon asupporting table-like member 36a. which. may if desired be madevertically adjust-.- able, a number of idler roils 31, a suctionv fan38. and a blast fan 39. 'I'he treated carpet materialtll, which now hasdeposited Aon an im'- pregnatedin its base the resinous plasticcomposition 24, isdrawn through the chamber 35 at the rate ofkapproximately 50 yards per hour.

The heating coils 36 liberate heat for drying the composition depositedon and partially impregnated in the carpet 40. The two fans 38 and 39the chamber 35. The purpose of this air flow is to expel -from thechamber 35 the contaminated air and vaporized composition, particularlysolvent, which ii allowed to remain would keep the coating on thematerial 4I) in a tacky condition. That is, it would not permit it todry. The contaminated air and gases expelled by the fan 39 may, ifdesired, be conducted to a suitable condensing apparatus for purposesofsalvagirig the solvent and other vaporized chemicals.

The treated carpet 40 after being dried passes out of the chamber 35through the aperture 4I and over the guide-roll 42. The carpet nextpasses over the drag or spike roll 43, which is caused to rotate in aclockwise direction by some suitable driving means (not shown) attachedto the shaft 43a. The roll 43 has arranged around its periphery a numberof spikes or teeth 44 that catch the carpet pile and cause the carpet tobe pulled through the` entire system. From the spike roll 43 the treatedcarpet passes to the takeup roll 45. This roll 45 is held in position bya shaft 45a which ts into the slot formed by the two upright members 46.The roll 45 is caused to rotate in a clockwise manner by means of thetwo rotating rolls 41 and 48 upon which the roll 45 rests. Both therolls 41 and 48 rotate in a counterclockwise manner. They may beconnected together by means of a belt and driven by some suitable commondriving means (not shown) connected to the shaft 49. If desired 'thespike roll 43 and the flexing roll I8, both of which rotate in providefor a continuous ow of fresh air through -to note that the adhesiveresinous plastic compositio'n 24 is not deposited simply as a layer onthe surface of the-threads forming the fabric base of this carpet but isactually impregnated in the base up to the point where the pile 3|leaves the base of the carpet. The impregnation of this composition 24between and around the jute threads 29 and 30 and the anchor threads 32cause these threads to be cemented firmly together in a compact manner.In addition to the above described means for effecting this impregnationthe unex- 4ing of the carpet itself as it leaves the flexing roll i8(Figure l) causes the composition 24 to be forced in and around thethreads of the base. It is to be understood, of course, that thecomposition 24 is plastic and flexible and therefor'e does not undulyharden or stiften the base of the fabric. As a result of the abovedescribed process, it is apparent that the pile 3i is firmly cemented tothe base threads of the carpet in such an eicient manner that the usualtendency for this pile to ravel out along the cut edges of -the carpetis greatly reduced if not ntirely'eliminated.

Referring now to Figure 4, the method of attaching two pieces ofpreviously treated carpet is clearly illustrated. 'I'he two pieces ofcarpet 5I and 52, which have previously been made frayproof by themethod outlined above in the dis cussion of Figure l, are placed side byside with their cut but fray-proof edges in contact with each other. Thetwo pieces of carpet are now rmly united to each other by means of theadhesive fabric strip 53. Asis shown at one end, this narrow fabricstrip is coated on its bottom side with a resinous adhesive composition54. This composition 54, which may be of the type given above in ExampleII, is of such a naturethat when moistened with a. suitable solvent suchas acetone its adhesive properties are made available. For uniting thetwo pieces of carpet l and 52, the strip 53 is moistened, as suggested,and then laid upon the two pieces of carpet with its moistened surfacein contact with the base of the carpets along the line where the two areto be joined to-' gether. Since the coating 24 on the two pieces ofcarpet 5| and 52 is of an adhesive nature it is advantageous to moistenit also along the edges of the carpet which are being united, beforeapplying the adhesive strip 53. The strip 53 is 'ilrmly pressed by handupon the two pieces of carpet and allowed to dry for a few minutes time.No heat are necessary for performing this uniting operation. When thedrying is completed the two pieces of carpet are united firmly togetherin a seamless manner and are now ready for use. Nu-

merous strips of carpet joined together in this vmanner majabe verysimply and easily placed upon the fioxaof the room or oilice which isdesired to be carpeted. When carpeting, of course, the base of thecarpet with the attached strip 53, is placed next to the floor. 'I'hiseasy and efficient method o f joining separate pieces of carpet in aseamless manner permits of course, cutting the carpet in any desiredwidths. The edges,l of such a carpet, which fit against the walls of theroom are entirely fray-proof dueto the fray-proofing process in whichthe strips of carpet have been previously treated.

- In Figure 5 is illustrated a rug which has been made fray-proof andalso conformed to a predetermined pattern or design.Y 'I'his type of rugis made by first impregnating the base of the rug with the adhesivesynthetic resin plaster composition 24 according to the abovel describedfrayproong process. Then a section is cut 'out of the body of the rugand this section replaced with the similarly shaped but differentcolored section 55. This section 55 is advantageously previously madefray-proof according to my invention. The section 55 is firmly joined tothe body of the rug 55 by means of the adhesive fabric strip 53,described above. For purposes of illustration the simple example shownin Figure 5 has been selected but it will be apparent to those skilledin the art that various and more complicated artistic rug designs may beeiected by this method.

For the sake of brevity and clear understanding the detailed descriptiongiven above.illus trates my invention, by way of example,`as applied tocarpet and other floor covering materials, however, it is to beunderstood that my invention may be applied equally as'well toupholstery materials. For example, furniture coverings, wall coverings,and vehicle seat coverings made fromv .various types of pile fabrics maybe rendered fray-proof and `conformed to various patterns and designs byuse ofthe above described process and apparatus.

It is further understood that my invention is not limited to the specicmaterials, apparatus and processes described hereinabove by way ofexample but is subject to various modications the scope of which is tobe limited only by the prior art and the appended claims.

What I claim is:

1. A method of rendering rug and carpet material fray proof comprising,bending the material in a semicircular form around a rotating roll withthe/ pile portion of the material in contact with said roll to renderthe base of said material pervious to the fray proofing composition tobe applied thereto, dropping an adhesive syntion entering the pileportion of said material,

passing the bent material and deposited composition under animpregnating roll for effecting further impregnation of said base,` andfinally passing said treated material through an oven provided with acontinuous fiow of hot air to dry said composition.

.2. A method 'of treating fabrics having a woven fabric base and a pilecovering consisting in suiiiciently flexing the fabric with the baseupward to create relatively large interstices between the threads ofsaid base, depositing a liquid fray-proofing composition directly uponsaid base and within said interstices without any substantial amount ofsaid composition penetrating into said pile, and drying the appliedcomposition.

3. A method of treating fabrics having a `woven fabric base and a pilecovering consisting in sufficiently flexing the fabric with the baseupward to create relatively large interstices between the threads ofsaid base, depositing an adhesive synthetic resin plastic compositiondirectly upon said base and within said interstices without anysubstantial amount of said composition penezrating into said pile, anddrying the applied composition.

4.' A method of treating napped fabrics having a wofven fabric base anda nap covering which comprisesexing said fabric to enlarge the openingsbetween the threads of said base and to simultaneously compress the nap,depositing directly upon the threads of said/ iiexed base and in theopenings therein an adhesive plastic composition, said flexed conditionof the fabric insuring thorough impregnation of the base with saidcomposition and inhibiting penetration of thel composition into the napportion 5 or the fabric.

' THEODORE J. BOWES.

